Inspection device utilizing eddy currents

ABSTRACT

An exemplary method of inspecting a component includes, among other things, securing an inspection probe body relative to a component, using a sensor assembly housed within the inspection probe body to induce an eddy current in a target area of the component, the target area having a target surface that is spaced from the sensor assembly, sensing a parameter of the eddy current in the component using the sensor assembly, and determining a position of the target surface of the component relative to the inspection probe body using the parameter of eddy current from the sensing.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No. 12/713410filed on Feb. 26, 2010.

BACKGROUND

This invention relates generally to an inspection device. Moreparticularly, this invention relates to an inspection probe thatutilizes eddy currents.

Turbo machinery, such as gas turbine engines are known and includemultiple sections, such as a fan section, a compression section, acombustor section, and a turbine section. During stable operation, thefan section moves air into the machinery. The air is compressed as theair flows through the compression section. The compressed air is thenmixed with fuel and combusted in the combustor section. Products of thecombustion are expanded in the turbine section to rotatably drive themachinery.

The performance of the machinery depends, in part, on relationships andinterfaces between components of the machinery. Accordingly, componentsof the machinery are periodically inspected to determine theirdimensions, clearances, spacing, and other information. The informationobtained during the inspection can highlight potential relationship andinterface issues.

For example, the size of components can change as the components wearduring machinery operation, machinery cleaning, machinery maintenance,etc. Worn components can result in inefficiencies. In one specificexample, disks in the turbine section of an engine include slots forholding turbine blades. The slots have a relatively complex geometry andare sometimes difficult to measure due to their axial depth. Thedimensions of the slots change when the disk erodes during cleaning. Theslots in the eroded disk may fail to securely hold the turbine blades.

SUMMARY

A method of inspecting a component according to an exemplarynon-limiting aspect of the present disclosure includes, among otherthings, securing an inspection probe body relative to a component, usinga sensor assembly housed within the inspection probe body to induce aneddy current in a target area of the component. The target area has atarget surface that is spaced from the sensor assembly. The methodfurther includes sensing a parameter of the eddy current in thecomponent using the sensor assembly, and determining a position of thetarget surface of the component relative to the inspection probe bodyusing the parameter of eddy current sensed from the sensing.

In another example of the foregoing method, a voltage of the eddycurrent sensed is the parameter of the eddy current used in thedetermining.

In another example of any of the foregoing methods, the determiningcomprises determining a position of the first surface of the componentrelative to a reference surface of the component.

Another example of any of the foregoing methods includes using a secondsensor assembly housed within the inspection probe body to induce aneddy current in a second area of the component. The second area has asecond surface and the second sensor assembly spaced from the secondsurface. The method includes determining spacing between the firstsurface, the reference surface, the second surface, or some combinationof these.

In another example of any of the foregoing methods, the first surfaceand the reference surface establish portions of a blade slot in aturbine engine disk.

In another example of any of the foregoing methods, the first surface istransverse the reference surface.

Another example of any of the foregoing methods includes actuatingportions of the inspection probe body to secure the inspection probebody relative to the component.

In another example of any of the foregoing methods, the component is adisk in a turbine engine.

In another example of any of the foregoing methods, the target surfaceestablishes a portion of an axially extending slot within the disk.

Another example of any of the foregoing methods includes moving theinspection probe body into contact with the component during thesecuring using an actuator.

In another example of any of the foregoing methods, the sensor assemblyis entirely spaced from the target surface.

Another example of any of the foregoing methods includes contacting aportion of the component with the inspection probe body during thesecuring.

Another example of any of the foregoing methods includes contacting theportion of the component with the inspection probe body at a positionthat is directly adjacent the sensor assembly.

In another example of any of the foregoing methods, the inspection probebody contacts the portion of the component at one or more referencesurfaces and further comprising calculating at least one distancebetween the one or more reference surfaces and the target surface.

In another example of any of the foregoing methods, the sensor assemblyis a first sensor assembly and the target surface is a first targetsurface. At least one second sensor assembly is housed within theinspection probe body. The at least one second sensor assembly isassociated with at least one respective second target surface of thecomponent. The method includes calculating the position of the at leastone second target surface relative to the first target surface.

A method of inspecting a component according to another exemplarynon-limiting aspect of the present disclosure includes, among otherthings, moving an inspection probe body into contact with a portion ofturbine machinery component, using a sensor assembly housed within theinspection probe body to induce an eddy current in a target area of theturbine machinery component. The target area having a target surfacethat is spaced from the sensor assembly. The method includes sensing aparameter of the eddy current in the turbine machinery component usingthe sensor assembly, and determining a position of the target surface ofthe component relative to the inspection probe using the parameter ofeddy current sensed in the sensing.

These and other features of the example disclosure can be bestunderstood from the following specification and drawings, the followingof which is a brief description:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-section of an example gas turbine engine.

FIG. 2 shows a perspective view of an example inspection probe.

FIG. 3 shows a perspective view of a probe body in the FIG. 2 inspectionprobe.

FIG. 4 shows a perspective view of an example disk of the FIG. 1 enginehaving a blade slot.

FIG. 5 shows a partial schematic side view of the FIG. 2 inspectionprobe in an installed position within the FIG. 3 blade slot.

FIG. 6 shows an example lift-off curve used to determine a position of acomponent in the FIG. 1 engine.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates an example gas turbine engine 10, whichis an example type of turbine machinery. The example gas turbine engine10 includes (in serial flow communication) a fan section 14, alow-pressure compressor 18, a high-pressure compressor 22, a combustor26, a high-pressure turbine 30, and a low-pressure turbine 34. The gasturbine engine 10 is circumferentially disposed about an enginecenterline X.

During operation, air is pulled into the gas turbine engine 10 by thefan section 14. Some of the air moves to a core of the gas turbineengine 10 and is pressurized by the compressors 18 and 22, mixed withfuel, and burned in the combustor 26. The turbines 30 and 34 extractenergy from the hot combustion gases flowing from the combustor 26.

In a two-spool design, the high-pressure turbine 30 utilizes theextracted energy from the hot combustion gases to power thehigh-pressure compressor 22 through a high speed shaft 38, and thelow-pressure turbine 34 utilizes the extracted energy from the hotcombustion gases to power the low-pressure compressor 18 and the fansection 14 through a low speed shaft 42.

The examples described in this disclosure are not limited to thetwo-spool engine architecture described, however, and may be used inother architectures, such as a single-spool axial design, a three-spoolaxial design, and still other architectures. Further, although theexamples discussed herein are described with regard to the gas turbineengine 10, those having skill in this art and the benefit of thisdisclosure will understand that other examples may include other typesof turbine machinery or any component comprising at least someconductive material.

Referring to FIGS. 2-5 with continuing reference to FIG. 1, an exampleinspection probe assembly 50 includes a multiple of eddy current sensors54 housed in a probe body 58. The eddy current sensors 54 form a portionof an eddy current sensor assembly. The eddy current sensors 54 arelinked to a controller 62 and an eddy current generator 64, which alsoform a portion of the example eddy current sensor assembly. Access holes65 in the probe body 58 facilitate securing the sensor tips 54 relativeto the probe body 58.

In this example, a pneumatic cylinder 66 is mounted to a housing 70 andthe probe body 58. The cylinder 66 is configured to move the probe body58 and the eddy current sensors 54 relative to the housing 70. A pinarrangement 74 secures the probe body 58 to a shaft of the cylinder 66.

The example inspection probe assembly 50 is used to determine dimensionsof a turbine blade slot 78 established within a turbine disk 82 of thegas turbine engine 10. The turbine disk 82 and the turbine blade slot 78are components of the high-pressure turbine 30 in this example. Theturbine blade slot 78 is configured to slidably receive a turbine blade.

As known, processes used to clean the disk, such as grit blastingprocesses, can alter the profile of the turbine blade slot 78. Theexample inspection probe assembly 50 can identify altered areas of theturbine blade slot 78.

The probe body 58 includes a plurality of teeth 86 a-86 c configured tobe received within a corresponding area 90 a-90 c of the disk 82. Theexample probe body 58 is configured to have a profile that is similar tothe profile of the slot 78.

In this example, the probe body 58 is sized such that the teeth 86 bcontact the disk 82, and the teeth 86 a and 86 c are spaced from thedisk 82 when the inspection probe assembly 50 is in the installedposition shown in FIG. 4. The installed position is a positionappropriate for determining spacing of the slot 78.

To move the inspection probe assembly 50 to the installed position, theprobe body 58 is first slid axially into the slot 78. Cylindrical stops94 limit the axial sliding movement in this example.

The cylinder 66 is then activated, which pulls the probe body 58radially outward relative to the housing 70. Contact between the teeth86 b and the disk 82 limits further radial movement of the probe body58. In another example, the probe body 58 is moved manually rather thanusing the cylinder 66.

In this example, a surface of the probe body 58 contacts the disk 82 atthe teeth 86 b. The probe body 58 is made from a glass reinforcedplastic material. Other suitable materials include other materials thatare not likely to scratch or otherwise mar the surfaces of the disk 82.

Notably, the eddy current sensors 54 in the area of the teeth 86 bcontacting the disk 82 are positioned below the surface of the probebody 58 such that the eddy current sensors 54 in this area are spacedfrom the disk 82.

The eddy current sensors 54 in other areas of the probe body 58 are alsopositioned below the surface of the probe body 58. In another example,these eddy current sensors 54 are flush with the surface of the probebody 58. As can be appreciated, eddy current sensors 54 flush with thesurface of the probe body 58 in the other areas would still be spacedfrom the disk 82 as these other areas of the probe body 58 are spacedfrom the disk 82.

In this example, the teeth 86 b contact the disk 82 at referencesurfaces 98. Dimensions and other measurements associated with the slot78 are established, in part, using the location of the referencesurfaces 98.

The eddy current sensors 54 are distributed throughout the probe body58. Each of the eddy current sensors 54 is configured to induce an eddycurrent in an associated area of the disk 82. Each of those areas have atarget surface 102 that establishes a portion of the slot 78. In thisexample, the target surface 102 corresponds to the area of the disk 82closest to the respective eddy current sensor tip 54. The eddy currentsensors 54 are positioned in various radial and axial positions withinthe probe body 58. Target surfaces 102 are thus also distributed in thismanner.

After inducing the eddy current, the eddy current sensors 54 detect aparameter of the eddy current such as the voltage of the eddy current inthat area of the disk 82. A computer 106, using the strength of thevoltage, then determines a distance between each of the eddy currentsensors 54 and the associated target surface 102. The computer 106 actsas a data acquisition and analysis system for the inspection probeassembly 50.

The computer 106 associates one of the eddy current sensors 54 detectinga lower eddy current voltage as being spaced closer to the target area102 associated with that eddy current sensor tip 54 than another eddycurrent sensor tip 54 that detects a higher eddy current in anothertarget surface 102. In one example, the computer 106 utilizes a lift-offcurve 110 (FIG. 5) when determining more precise spacing.

The computer 106 then establishes dimensions of the slot 78, forexample, using the distances between each of the eddy current sensors 54and their associated target surface 102. The computer 106 also uses thelocation of the reference surface 98 in one example.

The positioning of the probe body 58 relative to the slot 78 isreproducible in another slot 78 a. Thus the computer 106 may output acomparison of spacing in the slot 78 to the slot 78 a. Aligning theprobe body 58 relative to the reference surfaces 98 in the slot 78, andthe aligning the reference surfaces 98 a in the slot 78 a facilitatesreproducing the position of the probe body 58. The cylinder 66 isdeactivated so that the probe body 58 can be moved from the installedposition within the slot 78 to an installed position within the slot 78a.

The dimensioning of the probe body 58 and the eddy current sensors 54 isknown and remains consistent and stable whether the probe body 58 is inthe slot 78 or the slot 78 a. Thus, differences in voltages detected bythe eddy current sensors 54 can typically be attributed to differencesin the surfaces of the slots 78 and 78 a.

The example computer 106 uses the dimensions to detect dimensionalirregularities in the slot 78. In one example, the dimensionalinformation is compared to acceptable dimensions to determineirregularities. The computer 106 may establish a general profile of theslot 78 using the dimensional information.

Features of this invention include a relatively simple inspection toolthat is easily transported, installed, and set-up. The invention alsoprovides information about variations in the surface along the axialdepth of the inspected component.

Although a preferred embodiment has been disclosed, a worker of ordinaryskill in this art would recognize that certain modifications would comewithin the scope of this invention. For that reason, the followingclaims should be studied to determine the true scope and content of thisinvention.

1. A method of inspecting a component, comprising: (a) securing aninspection probe body relative to a component; (b) using a sensorassembly housed within the inspection probe body to induce an eddycurrent in a target area of the component, the target area having atarget surface that is spaced from the sensor assembly; (c) sensing aparameter of the eddy current in the component using the sensorassembly; and (d) determining a position of the target surface of thecomponent relative to the inspection probe body using the parameter ofeddy current sensed in said step (c).
 2. The method of claim 1, whereina voltage of the eddy current sensed in said step (c) is the parameterof the eddy current used in said step (d).
 3. The method of claim 1,wherein said step (d) comprises determining a position of the firstsurface of the component relative to a reference surface of thecomponent.
 4. The method of claim 3, including using a second sensorassembly housed within the inspection probe body to induce an eddycurrent in a second area of the component, the second area having asecond surface and the second sensor assembly spaced from the secondsurface, and determining spacing between the first surface, thereference surface, the second surface, or some combination of these. 5.The method of claim 3, wherein the first surface and the referencesurface establish portions of a blade slot in a turbine engine disk. 6.The method of claim 3, wherein the first surface is transverse thereference surface.
 7. The method of claim 1, including actuatingportions of the inspection probe body to secure the inspection probebody relative to the component.
 8. The method of claim 1, wherein thecomponent is a disk in a turbine engine.
 9. The method of claim 8,wherein the target surface establishes a portion of an axially extendingslot within the disk.
 10. The method of claim 1, further comprisingmoving the inspection probe body into contact with the component duringthe securing using an actuator.
 11. The method of claim 1, wherein thesensor assembly is entirely spaced from the target surface.
 12. Themethod of claim 1, further comprising contacting a portion of thecomponent with the inspection probe body during the securing.
 13. Themethod of claim 12, further comprising contacting the portion of thecomponent with the inspection probe body at a position that is directlyadjacent the sensor assembly.
 14. The method of claim 1, wherein theinspection probe body contacts the portion of the component at one ormore reference surfaces and further comprising calculating at least onedistance between the one or more reference surfaces and the targetsurface.
 15. The method of claim 1, wherein the sensor assembly is afirst sensor assembly and the target surface is a first target surface,and including at least one second sensor assembly housed within theinspection probe body, the at least one second sensor assemblyassociated with at least one respective second target surface of thecomponent, and further comprising calculating the position of the atleast one second target surface relative to the first target surface.16. A method of inspecting a component, comprising: (a) moving aninspection probe body into contact with a portion of turbine machinerycomponent; (b) using a sensor assembly housed within the inspectionprobe body to induce an eddy current in a target area of the turbinemachinery component, the target area having a target surface that isspaced from the sensor assembly; (c) sensing a parameter of the eddycurrent in the turbine machinery component using the sensor assembly;and (d) determining a position of the target surface of the componentrelative to the inspection probe using the parameter of eddy currentsensed in said step (c).